LIFTING EQUIPMENT

INSPECTION (PRACTICAL)
ORGANISED BY
FACTORIES INSPECTORATE
PORTHARCOURT
PRESENTED
BY
EMMANUEL NNAJI-ONWUKA
FIG. 1
GENERAL
The importance of efficient examination after testing cannot be proclaimed
too often or too loudly. The most exact test will reveal nothing in itself
except in the comparatively rare case of an actual break. The most carefully
made lifting gear may have a fault which can only be detected by the
painstaking eye of the experienced examiner.
The first qualification required of an examiner is onesty of purpose. e is
doing a responsible !ob" one on which the lives of other may depend. #nly
he can know whether he has given of his best in the examination of each
piece of gear unless a subsequent failure points to a careless examination
and then it will be too late. It is a matter between the man and his
conscience. If he has not a conscience then he has no business being lifting
equipment examiner.
The second qualification is the $know%how and why&" or experience and
technical knowledge. #nly time and attention to detail can give the former
and it is hoped that this course will supply at lest part of the latter. $'ny fool
can condemn everything he examines and be quite sure that he will never
make a mistake but the really competent person knows !ust what to scrap
and what to pass. yet takes no risk&.
aving stated the obvious" you are welcome to the practical section.
The ob!ective here is to give as much practical (real situation exposure to the
extent time" space and materials can permit
For the purpose of records few samples of various lifting equipment and
gears have been briefly discussed here to reinforce the knowledge you have
acquired from the class room sessions. #bviously very few indeed.
FIG. )
*'T+,I'-. /.+0 I1 T+ *'1/F'2T/,+ #F -IFTI1G G+',
They 're 3rincipally Iron" .teel" 'lloy .teels" 2ast Iron" 2ast .teel"
*alleable 2ast Iron"
1on% Ferrous *etals 42opper" 5rass" 5ron6e 7 'luminum8.
*onel *etal 4'lloy #f 1ickel 'nd 2opper8
Timber and .ynthetic Fibers
*aterials used in the manufacture of lifting gear must be strong to offer
considerable resistance to breaking under load.
The material must be capable of resisting shock load by stretching before
breaking90/2TI-IT:
It must be hard enough to resist wear; it must also as much as possible resist
corrosion.
From the manufacturing point of view it is desirable that it can be easily
shaped to si6e either by forging" casting or machining and that it should be
wieldable by one or more of the common processes such as resistance"
electric arc" gas or forge welding
It is believed that the examiner must have a good understanding of the
defects inherent in the different manufacturing process as to be able to detect
them when encountered.
It is obvious that before carrying out any examination" the equipment must
be clean and free from dirt" grease or scale. . 2racks are often hidden by
being filled up with rust or scale"
FIG. <
FINDING THE SAFE WORKING LOAD
#ne of the most important duties of the Tester and +xaminer is to assess the
safe working load of the gear submitted to him. #verrating of the safe
working load is still only too common. The Tester must be ever watchful and
must on no account assume that because the gear has been previously
stamped with a safe working load it is necessarily correct.
To apply an unduly high proof -oad may cause serious damage by distortion
and causing permanent bends which will be costly to correct or may cause
the gear to be scrapped. =hereas if the gear had not been over loaded it
might have served well at a lesser load. #n the other hand the fact that no
distortion takes place under a proof load cannot be taken as an infallible
indication that the loading is correct. *etal in a work hardened condition
may well show no distortion under a proof load steadily applied but owing
to its brittleness would be liable to fail under shock" this danger is greatly
aggravated by having too high a safe working load.
In general the safe working load of a piece of gear cannot be assessed from
the results of a routine proof test. 2ases do however arise where owing to a
complicated shape" calculation of the stresses becomes extremely difficult"
or only an approximation can be made; then" if the physical condition of the
metal" ultimate tensile strength and yield point have first been found by tests"
it is often possible to check calculations by making accurate readings of the
amount of distortion under a series of overload but in doing this type of test
the part is usually damaged beyond repair.
FIG. >
The tester?s !ob is to check the safe working load of gear sent in for testing"
not to assess the safe working load of new gear or to design fittings for new
or old gear. +xperience will give him a good idea of the various si6es of
standard fittings required for different loads and it is hoped that the
knowledge of the examiner on -oads ( .tress distribution will be a further
help in !udging what the loads actually are.
's a further aid" a number of Tables of safe -oads for various fittings are
given in 'ppendix 1. In a book of this si6e it would be impossible to make
the Table cover every possible variation in si6e of the fittings" they have
being chosen rather for guide and cover the more common si6es. 5y their
use it should be possible to !udge whether or not a given piece of gear or
component thereof" is suitable for the load stamped upon it. =here the
information given in the Table is insufficient to make this !udgment" the
matter should be referred to a person qualified to make the necessary
calculations in full. In general the Tables have been chosen to tell you
whether a given fitting is suitable for a certain safe working load rather than
to say what si6e fitting should be used for a given safe working load.
FIG. @
'33+10IA 1
Safe working load proof load
/nder )B tons ... .. .. )@ per cent
)B C @B tons ... .. .. @ tons
#ver @B tons ... .. .. 1B per cent
In the case of a crane with its accessory gear the proof load shall be applied
as followsD%
i8 =here reasonably practicable by hoisting movable weights; or
ii8 In other cases by maintaining the load by means of an accurate
spring or hydraulic balance or similar device for a period of not
less than five minutes. =here movable test weights are used the
crane shall be swung" with the load suspended" as far as possible
in both directions. =here a spring or hydraulic balance or similar
device is employed it shall be sufficient if the proof load is applied
with the crane swung as far as practicable first in one direction
and then in the other. In each case the crane shall be tested at the
smallest angle to the hori6ontal at which it will operate and this
angle shall be stated in the certificate of the test.
FIG. E
in excess of the
safe working
load
b8 +very crane" crab" sheer C legs" teagle" transporter or runway"
with its accessory gear" shall be tested with a proof load which
shall not be less than the followingD%
Safe working load proof load
/nder )B tons ... .. .. )@ per cent
)B C @B tons ... .. .. @ tons
#ver @B tons ... .. .. 1B per cent
In the case of a crane having a variable radius it shall be tested with a proof
load applied a the maximum and minimum working radii. 't each such
radius the crane shall be swung as far as possible in both directions with the
corresponding proof load suspended.
In the case of hydraulic cranes where" owing to the limitation of pressure it
is impossible to hoist a load of )@F in excess of the safe working load" it
shall be sufficient to hoist the greatest possible load.
FIG. G
in excess of the
safe working
load
c8 +very article of lifting gear 4whether it is accessory to any lifting
appliance or not8 and every pulley block other than a pulley block
specially constructed for use with a crane to which it is
permanently attached and every chain shall be tested with a proof
load at least equal to that shown against it in the following tableD%
Article of gear Safe working load proof load
2hain sling ... .. ..
,ope sling ... .. ..
3late clamp ... .. ..
,ing ... .. .. ..
-ink ... .. .. ..
ook 4other than a rams%
orn hook8
.hackle ... .. ..
.wivel ... .. ..
+ye%bolt ... .. ..
/nder @B tons ... Twice the safe
=orking load
,amshorn hook .. @B tons to 1BB tons .afe working
-oads plus @B
Tons.
#ver 1BB tons ... #ne and a half
Times the safe
FIG. H
Twice the safe
working load
=orking load
3ulley blocks
.ingle sheave block ... Four times the
.afe working
-oad
*ultiple sheave block
with safe working load Twice the safe
up to and including working load
)B tons ... .. ..
*ultiple sheave block )B tons in
with safe working load excess of the
over )B tons up to and safe working
Including >B tons ... .. -oad
*ultiple sheave block #ne and a half
with safe working load times the safe
over >B tons .. .. .. =orking load
2hains 4other than calibrated load chains8 ... .. Twice the safe
=orking load
#ne and a half
2alibrated load chains ... .. .. .. .. Times the safe
=orking load
Force as exerted by a testing machine as the same thing. This is not the case
and distinction should be drawn.
FIG. I
'33+10IA II
T+ ,/+ #F T/*5 F#, 2'-2/-'TI#1 #F .=- F#, ,#3+.

FIG. 1B
.=- F#, 3#-:+.T+, .:*T+TI2 =+5I1G .-I1G
=eight is a particular force due to the action of gravity on a body and this is
measured in kilogrammes. #ther forces are expressed in 1ewton?s or
1 kilogramme%force 4kgf8J I.HBEE@1
1 ton%force 4tonf8 J I.IE>B)k1 exactly
or for practical purposes
1k1 J 1BB kgf or B.1 tonnef
and for our purposes the numerical value
of 1 kgf is the same as 1 kg.
FIG. 11
3roof -oad if applied by a testing machine" will" therefore" be expressed in
Kilonewtons. 5ut if applied by lifting dead weights will be expressed in kg
or tones.
arking of S!W!L! on Lifting Gear in etric "nit#
=ith the adoption of metric units 4..I. .ystem8 safe working loads of lifting
equipment are marked in these units as followsD
.afe =orking -oads of less than 1BBB kilogrammes 4kg8 shall be
marked in kg to the nearest whole kg.
.afe =orking -oads of 1BBB kg or more shall be marked in tones. The
letter $t& not $T& being used as an abbreviation. The value shall be
given to a single decimal place" except in the case of 1.)@tons which
shall be given to two decimal places.

=here the figure after the decimal point is $B& it shall be omitted.
This method avoids the possibility of metric markings being confused with
tons and cwts" as if the metric figure after the decimal place is read as cwts
the mistake will always be on the safe side" since" in fact" the single decimal
figure is always half the equivalent cwts.
For the purpose of converting existing tons and cwts on lifting gear to
metric" the tonne which is 1BBB kilogrammes and is equal to ))BB Imperial
pounds.
1ew 5ritish .tandards not only express ..=.- in tones but also give
dimensions in mm 4millimeters8 and in these cases the appropriate metric
FIG. 1)
..=.- will be found from the tables in the .tandards. =here existing gear
made in inch si6es is required to be re%stamped in metric a straight
conversion should be made from the ..=.- marked on the gear.
'33+10IA III
2#1L+,.I#1 T'5-+
The following are examples of the conversionsD
1 cwt @Bkg 1 Ton 1t 1Ton 11cwt 1 @t
1 Ton 1 cwt 1t 1Ton 1)cwt 1 Et
) cwt 1BBkg 1 Ton ) cwt 1 1t 1Ton 1)cwt 1 Et
1 Ton < cwt 1 1t 1Ton 1>cwt 1 Gt
@ cwt )@Bkg 1 Ton > cwt 1 )t 1Ton 1@cwt 1 Gt
1 Ton @ cwt 1 )@t 1Ton 1Ecwt 1 Ht
GM cwt <G@kg 1 Ton E cwt 1 <t 1Ton 1Gcwt 1 Ht
1 Ton G cwt 1 <t 1Ton 1Hcwt 1 It
1B cwt @BBkg 1 Ton H cwt 1 >t 1Ton 1Hcwt 1 It
1)M cwt E)@kg 1 Ton I cwt 1 >t )Ton )t
1@ cwt G@Bkg 1 Ton 1Bcwt 1 @t
It will be noted that in the case of" say" 1 ton <cwt the exact conversion
would be 1 .1@t but as the second decimal place is disregarded this becomes
1.1t
FIG. 1<
DIENSIONAL EAS"REENTS

Knowing where and how to carry out accurate dimensional checks on
various lifting gears is very important as it forms the bases for accurate
interpretation hence sound !udgment. Therefore the examiner should
acquaint with correct practice as demonstrated below
WIRE RO$ES
HOW TO EAS"RE WIRE RO$E
FIG! %
FIG. 1>
DIAETER OF WIRE RO$E
The components of a wire rope each have a small but definite si6e tolerance.
Therefore" the rope itself must have a diameter tolerance. 'll wire rope is
required to have a diameter at least equal to the nominal" or catalog" si6e9...
never smaller. .tandard ropes may exceed the nominal diameter by the
amounts shown belowD
'33+10IA IL
WIRE RO$E TOLERAN&ES
No'inal Dia'eter of
Rope In Inc(e#
"nder#i)e
Inc(e#
O*er#i)e
Inc(e#
B C
<
(
>
B
1
(
<)
1<
(
1E
C 1
1
(
H
B
<
(
E>
1
<
(
1E
C 1M B
1
(
1E
1
I
(
1E
C )N B
<
(
<)
)
@
(
1E
and larger B
1
(
H
T(e#e tolerance# do not appl+ to ele*ator rope#!
WHAT TO LOOK FOR IF ,O" HA-E RO$E TRO".LE
Kinking%3erhaps the rope has been kinked when it was being moved
from the reel or coil" or has been allowed to run loose and roll over to
form a kink.
&/t%3erhaps the wire rope has been run over by a tractor cleat when it was
laid out on the ground prior to installation.
0a''ed%3erhaps the rope has !umped the head sheave and become wedged
between the sheave and the housing of the machine.
FIG. 1@
&ro##1O*er $oint%#ften when the face of the drum has been filled with
turns of rope" the rope when positioning itself for the beginning of the
second" or even the third layer" will not come up to this position smoothly"
thus slapping the last turn on the layer below. This over a period of time can
be particularly hard on the rope. This is a condition which can be improved
by the installation of a riser which will ease the rope up into the new level"
or by the cutting back at the drum end at intervals to thus change the point of
contact.
&r/#(ing13erhaps the rope has been crushed by poor winding on an under%
si6ed drum.
Lack of L/2rication1is this important matter been neglected.
Re*er#e .end#1These are tough on any rope particularly when they are
close together. This condition can be improved by using larger sheaves and a
more flexible rope.
Fro)en S(ea*e1' sheave that won?t turn sharply means that the wire rope is
sawing its way down the length of the groove" and this is sure to cut down
the life of the rope.
.ad Align'ent1This can always result in the wire rope wearing itself out on
the side wall of a sheave.
FIG. 1E
Wrong Kind of &a2le13erhaps yours is a case of a boy being asked to do a
man?s work. 3erhaps the rope is of the wrong construction. 0oes the maker
have wide acceptanceO
Tig(t S(ea*e#1' tight sheave is sure to pin off the cable and reduce cable
life.
DR" AND REEL
&A$A&ITIES

-ength of rope in feet
2onstant x 4' P 58 x ' x 2
4'll 0imensions in Inches8
FIG.)
FIG. 1G
It is often necessary to know the approximate capacity of a
given drum or reel for a particular diameter rope. *aking
certain assumptions" it is 3ossible to resolve the mathematical
equation for this to a simple expression and constant. =e list
5elow these constants for standard rope diameters.
Ta2le of &on#tant# for 3 45%6
6
4
Dia'eter
Rope Inc(e#
/ltiplier
Dia'eter
Rope Inc(e#
/ltiplier
Dia'eter
Rope Inc(e#
/ltiplier
N >.1I
G
(H .<>) 1Q .BH@
<
(
H
1.HE 1 .)E) 1
G
(
H
.BG>
G
(
1E
1.<G 1M .)BG ) .BE@
M 1.B@ 1N .1EH )
1
(
H
.B@H
I
(
1E
.H)G 1<(H .1<H )
1
(
>
.B@)
E
(
H
.EGB 1 M .11E )
<
(
H
.B>E
Q .>E@ 1 @(H .BII 1M .B>)
Note7 In most cases the flange 4'8 will extend beyond the outer layer of the
rope" therefore the dimension 4'8 should be taken to the depth of the
spooled rope and not to the full depth of the flange.
FIG. 1H
INI" RE&OENDED TREAD DIAETERS OF SHEA-ES
AND DR"S 8IN&HES9
$LOW STEEL AND I$RO-ED $LOW STEEL RO$ES
Rope Dia!
Inc(e#
5 : ;
5 : %< Seale
%6 : ; N! R
5 : %< Warr!
5 : %5 F 5 :
4; F!S
5 : %<F
6 : %< Seale
5 : =;
N
@
(1E
<
(H
G
(1E
M
I
(1E
@
(H
Q
G
(H
1
1
1
(H
1N
1
<
(H
1M
1
@
(H
1Q
1
G
(H
)
)N
)M
1B
1<
1E
1H
)1
)<
)E
<1
<G
1)
1G
E)
E<
E<
H
11
1<
1@
1G
1I
)1
)@
<B
<>
<H
>)
>G
@1
@@
@I
E>
EH
G
I
11
1<
1@
1G
1I
))
)E
<B
<>
<G
>1
>@
>I
@)
@E
EB
EG
G@
E
H
1B
11
1<
1@
1E
1I
)<
)E
)I
<)
<E
<I
>)
>@
>I
@)
@H
E@
@
E
G
H
I
1B
11
1<
1E
1H
)B
))
)@
)G
)I
<1
<>
<E
>B
>@
This table applies to general ropes and not to special applications such as
mine hoists and elevators. *ine hoists generally use a drum%rope diameter
ratio of at least HBD1.
FIG. 1I
G"IDELINES
The following information is a guide to use for inspecting wire rope slings.
+xpensive ob!ects to be lifted" personal in!ury or property damage factors
determine the frequency of the inspection.
The user should store slings in a manner that will protect them from damage
by moisture" heat" corrosion or physical abuse.
The user should determine that the sling is being used in accordance with the
rated capacity as listed in the current catalog of the sling manufacturer.
'll slings should be inspected at some regular interval of time. This interval
can best be determined by the user and is dependent upon the particular use
of the sling and or company safety requirements. The interval must be within
the statutory limit such that safe use of the sling is assured at all times.
' sling should be inspected after any unusual situation that may have
damaged it" such as overload" accident or fire. It should not be placed back
in service until continued safe operation has been verified.
#nly persons with sufficient experience and knowledge to properly apply
the following criteria for re!ection when examining a given sling should
perform inspection. This is particularly important" since each of the 11 items
listed depends to some extent upon the !udgment of the inspector.
FIG. )B
The following should be considered criteria for re!ectionD
1. 5roken wire criteria
a. For strand laid and single part slings C ten randomly distributed
broken wires in one rope lay or five broken wires in one strand
in one rope lay.
b. For multi%part cable%laid and braided slings.
'33+1IA IL
,+R+2TI#1 2+2K -I.T
Allowa2le .roken Allowa2le .roken
Wire# per La+ or Strand# per Sling
Sling .od+ One .raid Lengt(
-ess than H part braid
2able laid
H part 7 greater braid
)B
)B
>B
1
1
)
1. +ither the broken wire count or broken strand count shall apply
separately to one braid length or one lay length in cable%laid body.
). 'brasion" scrubbing or peening causing loss of more than 1(< the
original diameter of outside individual wires.
<. +vidence or rope deterioration from corrosion.
>. Kinking" crushing or other damage that results in detrimental
distortion of the rope structure.
FIG. )1
@. 'ny evidence of heat damage including bare electrical conductor"
ground" or welding arc.
E. 'ny marked reduction in diameter either along the entire main
length or in one section.
G. /nlaying or opening up of a tucked splice.
H. 2ore protrusion along the main length.
I. +nd attachments that are cracked" deformed" worn or loosened.
1B. 'ny indication of strand or wire slippage in end attachments.
11. *ore than one broken wire in the vicinity of a 6inced%on or swaged
fitting; including resin%poured sockets
BE CAREFUL 3 THE TOES YOU SAVE MAY BE YOUR OWN.
FIG. ))
"SE RO$E FOR SLING 3 wire rope used for sling purposes are usually of
improved plow steel grade of either E x 1I constructions or E x <G
constructions. There is very little saving in cost in using rope of less tensile
strength as the labor involved in making a sling remains ropes constant.
.imilarly" there is no real economy for using old hoisting ropes to make
sling.
If a rope is no longer serviceable as a hoist rope" the mere action of splicing
loops into the ends reduces its strength still further and it is of little value In
picking up heavy loads. In fact" it is a used sling from the very start.
SHO&K LOADS 3 crane hooks should be started slowly until the sling
becomes taut and the load is suspended. The lifting or lowering speed of the
crane should be increased or decreased gradually. .udden starts or stops
place heavier loads or the sling. This action can be reasonably compared to
!amming the brakes on a speeding automobile.
A r/le of t(/'27 #(ock load# do/2le t(e #tre## on a #ling!
FIG. )<
G"IDELINE TO INS$E&TIONS > RE$ORTS
C +quipment" wire rope 7 wire rope slings.
1. *aintain all inspection records and reports for the length of time
deemed appropriate
). 3rior to each daily use" the following procedure is set as a
guideline.
a. 2heck all equipment functions.
b. -ower load blocks and check hooks for deformation or
cracks.
c. 0uring lowering procedure and the following raising cycle"
observe the rope and the revving. 3articular notice should be
paid to kinking" twisting or other deformities.
d. 2heck wire rope and slings for visual signs of anything
causing them to be unsafe to useD broken wires" excessive
wear" kinking or twisting. 3articular attention should be
given to a new damage during operation.
<. *onthly inspections are recommended with a signed report by an
authori6ed competent inspector. The *onthly ,eports should
include the inspection of the followingD
a. 'll functional operating mechanisms for excessive wear of
components" brake system parts and lubrication.
b. -imit .witches.
FIG. )>
c. 2rane hooks for excess throat opening or twisting along with a
visual for cracks.
d. =ire rope and revving for conditions causing possible removal.
e. =ire rope slings for excessive wear" broken wires" stretch"
kinking" twisting and mechanical abuse.
f. 'll end connectionsD hooks" shackles" turnbuckles" plate
clamps" sockets" etc. for excessive wear" distortion and
broken wires.
g. +lectrical apparatus for signs of pitting or deterioration of
controller containers push button stations" limit switches and
other electrical controls.
' Suarterly ,eport is suggested to combine the *onthly ,eports and be
signed by a responsible" competent authori6ed inspector.
'n 'nnual Inspection with signed report is suggested for the followingD
a. *agnetic particle test of crane hook for cracks
b. oist drum for wear or cracks
c. .tructural members for cracks" corrosion and distortion.
d. For loose structural unions such as bolts" rivets or weldments.

FIG. )@
FOR"LA FOR FIG"RING LINE $ARTS FOR FALLS
Total load to be lifted in Ibs. J RATIO
-ead line pulls in Ibs.
+.G" to find number of parts of line needed where weight of load and lead
line pull are established.
H>"GBB 4load8 Ibs. J 6!?; 8RATIO9
1B"BBB 4lead line pull8 Ibs.
,efer to H.>G in table below C 11 parts of line.
+.G." To find lead line pull needed when weight of load and number of parts
of line are established.
>>"BBB 4load8 Ibs. J %@A@@@ I2#!
>.<I 4ratio of @ part line8 8lead line p/ll9

A$$ENDIB -
FIG. )E
TA.LE FOR FIG"RING LINE $ARTS FOR FALLS
N/'2er of Ratio for Ratio for
$art# of 2ron)e 2/#(ed 2all 2earing
Line #(ea*e# #(ea*e#
1 B.IE B.IH
) 1.HG 1.I>
< ).GE ).HH
> <.@I <.H1
@ >.<I >.G1
E @.1E @.EB
G @.IB E.>G
H E.EB G.<)
I G.)G H.1E
1B G.I1 H.IH
11 H.@) I.GI
1) I.11 1B.EB
1< I.EH 11.>B
FIG. )G
RE&OENDED SAFE WORKING LOADS FOR REE-ED FALLS
Improved plow Q E x 1I steel core
1B"BBB Ibs. -ead line pulls at engine
.ron)e 2/#(ed .all 2earing
S(ea*e# in good S(ea*e# in good
N/'2er of part# condition #afe load condition #afe load
In fall# 8I2#!9 8I2#!9
1 H<BB I1)B
) 1E1BB 1HBBB
< )<>@B )E@@B
> <B<@B <>IBB
@ <EH@B ><BBB
E >)I@B @BHBB
G >HE@B @H>BB
H @>B@B E@HBB
I @I1BB G)I@B
1B E<H@B GIIBB
11 EH<@B HEEBB
1) G)@@B I<1@B
1< GEGBB II@@B
The above values are based on two fair%lead blocks between the engine and
the falls. For each additional fair%lead block and EF to the lead line pull for
bron6e bushed sheaves; and <F to the lead line pull for ball%bearing sheaves.
A$$L,ING WIRE RO$E &LI$S
FIG. )H
The only correct method of attaching /%bolt wire rope clips to rope ends is
shown in the illustration. The base of the clip bears against the live end of
the rope" while the $/& of the bolt presses against the dead end.
The clips are usually spaced about six rope diameters apart to give adequate
holding power.
5efore ropes are placed under tension the nuts on the clips should be
tightened. It is advisable to tighten them again after the load is on the rope to
take care of any reduction in the rope?s diameter caused by the weight or
tension to the load.
' wire rope thimble should be used in the loop eye to prevent kinking when
wire rope clips are used. The correct number of clips for safe application and
spacing distances are shown in the table below see also the sample shown.
FIG!=
FIG. )I
IDENTIFI&ATION OF C"D .OLT FOR WIRE &LI$
FIG!?
FIG. <B
EFFI&IEN&, OF WIRE RO$E &ONNE&TIONS
A# &o'pared to Safe Load# on Wire Rope
Fig/re T+pe of &onnection Efficienc+
1
)
<
>
@
E
G
=ire ,ope
.ockets C Tinc Type C property attached
=edge .ockets
2lips C 2rosby Type
Knot and 2lip 42ontractors Knot8
3late 2lamp C Three 5olt Type
.mooth 2lamp
.pliced +ye and Thimble
N& and smaller
<
(
@
& to Q&
G
(
H
& to 1&
1
1
(
H
& to 1M&
1
@
(
H
& to )&
)
1
(
H
& and larger
1BBF
1BBF
GBF
HBF
@BF
HBF
HBF
1BBF
I@F
HHF
H)F
G@F
GBF
FIG. <1
FIG.
T"RN."&KLES
=eldless 2onstruction Forged 'lloy .teel
+nd Fitting"
.tock 0iameter
4Inches8
.=- of 'ny
2ombination of Raw
+nd Fittings. +ye +nd
Fittings and .tub +nd
Fittings 4-bs8
.=- of 'ny
Turnbuckle
aving a ook
+nd Fitting 4-bs8
N
@(1E
<(H
M
@(H
Q
G(H
1
1N
1M
1Q
)
)M
)Q
@BB
HBB
1.)BB
).)BB
<.@BB
<.@BB
G.)BB
1B.BBB
1@.)BB
)1.>BB
)H.BBB
<G.BBB
EB.BBB
G@.BBB
>BB
GBB
1.BBB
1.@BB
).)@B
<.BBB
>.BBB
@.BBB
@.BBB
G.@BB
U
U
U
U
<)
E,E.OLTS
FIG!5
FIG. <<
E:a'ination of E+e2olt#
The following points should be looked forD%
i. The thread on the shank must be complete 4no broken threads8. It
must be a full thread 4no flats on top8. It must run true and must not be
deeper one side than the other. It should be checked with a thread
gauge and be a good fit in a standard tappered hole. The condition and
fit of the thread are of the utmost importance" particularly in the case
of service eyebolts which are moved from place to place as required in
lifting. .uch eyebolts are often sub!ected to rough usage. If the thread
is allowed top become imperfect there is a danger that in being
screwed into a hole the threads may become crossed caused causing
damage which will result in failure under load.
ii. The centre line of the shank must if continue upwards pass through
the centre of the eye. *isalignment may be due either to bad
workmanship or the shank may have become bent in service.
iii. 3articular attention should be given to the !unction of the shank and
the collar as cracks leading to failure are very liable to develop here
particularly if the radius is not an ample one. The examination of this
part preferable made with the aid of a glass. It is not advisable to
attempt to repair an eyebolt which has become bent at the root of the
shank
iv. The eye should be examined for cracks etc.
v. The eyebolt should be checked against Tables for strength bearing in
mind if necessary that the strength is greatly reduced if the load is
applied otherwise than in the line of the shank and that a dynamo
FIG. <>
eyebolt" which has only a relatively small diameter collar. Is
unsuitable for any angular loading.
vi. =ear in eye as for mild steel chains.
FIG ;
FIG. <@
E,E .OLTS
E,E .OLTS
% .houlder Type #nly
% Forged 2arbon .teel
Stock
Dia'eter
8Inc(e#9
SAFE WORKING LOADS 8L.S9 &ORRES$ONDING
TO ANGLE OF $"LL
-ertical ;E 5@ ?E
Le## t(an ?E
N
@
(1E
<
(H
M
@
(H
Q
G
(H
1
1
1
(>
1
1
()
@BB
HBB
1")BB
)")BB
<"@BB
@")BB
G")BB
1B"BBB
1@")BB
)1">BB
,educe
Lertical
-oads
5y
>@F
,educe
Lertical
-oads
5y
E@F
,educe
Lertical
-oads
5y
G@F




















































N
O
T
R
E
&
O

E
N
D
E
D
1oteD ..=.-. for plain 4shoulder less8 eye bolts are same as for shoulder bolts under
vertical load. 'ngular loading is not recommended.
FIG. <E
HOOKS
FIG. <G
FIG!6
E:a'ination of Hook#
i. 0istortion" check with Table or 0rawing to ascertain whether hook
has opened out. 'lso that si6es are correct for load to be carried" if
opening of the hook has increased by more than one%fifth of its correct
measurement" scrap the hook.
ii. +xamine for cracks" nicks" etc" paying particular attention to the inside
of the hook. 'ny nick" scores or place; where the metal has been
hammered back into itself 4gall marks8 should be filed out so as to
remove the defect and blended away at each side to form a smooth
curve. If the amount of metal removed is more than 1(E> per 1 of
depth of the section. The hook should be scrapped. .
iii. =ear in eye allowance as for steel chain. =ear in hook HF of depth
may be allowed. ,ound section hooks are best measured with the
gauge" recommended for steel chasing" if within the range of that
instrument. =ear in a hook is often repaired by building up with are or
gas welding. =hile many successful repairs have undoubtedly been
made by these
*ethods here are on record some failures it is difficult to replace the
wear with weld metal without creating some degree of notch effect at
the !unction with the parent metal which may under the severe loading
likely in the bed of a ook. 0evelop into a crack.
Indeed the welding may well be more harmful than the wear which it
repairs; on balance therefore the practice is not recommend it is
important that any steel hook other part repaired by welding or any
FIG. <H
process involving heating should be heat treated to the same
specification as used in its *anufacture" before being put into service
after Testing re%examine for any new cracks which may have
developed
Note71 ' crack is taken as meaning a ham line or marks which aright
develop as a result of use or overloading or during manufacture.
Theses whether present before or after testing should lead to
re!ection ' score or nick is taken as meaning a mark or marks
caused by the hook hitting sharp edge 1icks on the inside are
much more serious than on the inside ooks -ine is an
imaginary line running from the being point of the load on the
hook to the centre of the top of the shank.

ii. 2heck in the case of swivel hooks that they turn freely.
iii. 2heck shank for soundness of thread" fit of thread in nut"
completeness of thread" etc. 4see +yebolts8.
iv. +xamine particularly any change of section in the shank for signs of
cracks. .uch as at the roots of threads" under collar or at cotter holes.
In general the shanks of hooks and eyes should be screwed and fitted with
nut" so that the assembly can be dismantled for inspection. Larious means
are used to prevent the nut from slacking back and it is part of the duty of
the examiner to satisfy him that the nut is properly secured.
'ssemblies which cannot easily be dismantled for inspection present a
difficult problem to the examiner. =here the shank is screwed and fitted
FIG. <I
with nut it is strongly recommended that it should be removed from its
housing for inspection" even though this may I involve chipping away
welding or riveting used to secure the nut. ooks or eyes secured in position
by the riveting over of t he unscrewed shank are unsuitable for any but the
lightest duties" as the shank cannot be exposed for examination.
=hen examining items so secured" the riveting should be carefully riveting
should be of a definite pan o r snap shape" if the river head is approximately
flush with the surrounding metal a countersink with a depth at leas t equal
to one quarter of shank diameter should be provided. The shank should be
careful examined for any bending and while turning freely in its housing
should have no excessive slack.
' widely used shank for hooks and swivels is that known as the solid swivel
Type&. 't the forging stage of manufacture the shank is formed with an
enlargement or collar at its end D the bow which has been drilled with a hole
to take the enlarged part of the shank and it is then squee6ed in a press so
that the hole is reduced in si6e to fit the shank. The bow being now retained
in position by the end of the shank. This type of shank has a very good
record of safety. 3robably due to the ample radiuses usually provided under
the enlarged head and at the change of section form hook to shank. '
careful examinant on should made to ensure that the shank is a good fit in
the bow or other housing and that the shank is not bent. In some designs the
shank is long enough to allow sufficient longitudinal movement for the radii
at either end to be examined. The final decision as to whether a shank which
cannot be exposed for examination should be passed nuts rest with the
competent person. In this case the tester or examiner.
FIG. >B
In general all screwed shanks should be exposed for examination. 5e very
wary of riveted shanks but solid swivel types of shank maybe passed in the
absence of any indication to the country.
The foregoing remarks illustrate the fault to be met within the basic items of
lifting gear and should serve as a guide to what may be found in the many
different items met with in practice which are too numerous to the deal with
a detail here. The following notice of a more general nation will be helpfulD
FIG. >1
SHA&KLES
FIG!<
5#= .'2K-+ $0& .'2K-+
There are two types of shackles commonly used in rigging. They are the
anchor 4bow type8 shackle and chain 4$0& type8 shackle both of which are
available with screw pins or round pins.
FIG. >)
.hackles" like most other rigging hardware are si6ed by the diameter of the
steel in the bow section rather than the pin si6e they should only be of forged
alloy steel.

Ne*er replace t(e #(ackle pin wit( a 2oltA onl+ t(e proper fitted pin
#(o/ld 2e /#ed! .olt# are not intended to take t(e 2ending t(at i#
nor'all+ applied to t(e pin!
Ne*er /#e a #(ackle if t(e di#tance 2etween t(e e+e# i# greater t(an
li#ted in t(e following ta2le!
FIG. ><
FIG.1#
'll pins must be straight and all screw pins must be completely seated"
2otter pins must be used with all round pin shackles.
.hackles worn in the crown or the pin by more than 1BF of the original
diameter should be destroyed.
1ever allow a shackle to be pulled at an angle because the capacity will be
tremendously reduced. 2entrali6e whatever is being hoisted on the pin by
suitable washers of spacers.
0o not use screw pin shackles if the pin can roll under load and unscrew.
E:a'ination of S(ackle#
Before proof testing examine for
i. .i6es conforming to tables for loads.
ii. Free working of pin.
iii. =ear on thread of screw pin shackles. Thread should be hand tight.
.hould be complete. 1ot have flats on top of the thread. The section
FIG. >>
of the thread can be checked with a thread gauge. =hen the shackle
pin is screwed into the threaded hole from the wrong side there should
be no more than a very slight wobble.
iv. 'lignment of the holes on opposite sides of the shackle. The untapped
hole is sometimes made very much too large for the pin so that when
the pin is screwed home it does not bear on the plain hole at all. Thus
putting undue strain on the shackle when it is loaded.
v. In the case of bolt and nut pins" the nut must !am on the end of the
thread before gripping the shackle" thus allowing the bolt and nut to
revolve freely in the shackle even though tightened up to the
maximum extent.
vi. =ear in pin or bow of shackle" allowable wear as per steel chain.
vii. 0ents" nicks or cracks as I result of service. These if at all severe will
!ustify the article being scrapped as they are possible sources of
weakness under shock conditions
After proof testing examine for:-
i. 0istortion which may have taken place under load.
ii. Free working of pin" has a bent in testO
iii. 2racks which may have developed as a result of test.
FIG.11
FIG. >@
NOTE71 In the older types of shackles made of iron which often had the
$pins& formed by wrapping a piece round a bar and welding. 3articular
attention should be given to the examination of the sides of the shackles
ad!acent to the $pins&.
The soundness of a shackle can be !udge by the $ring&. =hen struck with a
hammer it thou I give a clear bell%like sound. If it is cracked it will give a
dead sound
FIG. >E
&HAIN SLINGS
&(ain# Sling#
'8 2heck si6e of chain" egg links" rings" hooks etc. with Tables and
make sure that they are suitable for the loads called for.
58 +xamine before proof testing for stretch due to over%loading or
wear. If possible hang the sling up and compare the lengths of the
legs in the case of multi%legged slings. #ne leg longer than the
others will usually indicate uneven loading in service. If records
are available" compare present length with last recorded length.
4ii8 +xamine hooks for opening or distortion. If they are
5ritish .tandard hooks compare opening with Tables" if
of special design compare with drawing. If not available"
reference should be made to the customer or original
specification. .lightly deformed hooks can be reset but if
any considerable degree of resetting is required the hooks
should be renewed.
FIG. >G
4iii8 +xamine rings" pear%shaped links and other fittings for
distortion. If the repair required is at all considerable they
should be replaced. It is particularly important that rings
should be truly circular.
28 4i8 +xamine for bent or twisted links. .uch links unless only
slightly distorted should be replaced as they are nearly
always associated with a nick in the side of the link
caused by passing round a sharp ob!ect. .uch a nick
would form a permanent point of weakness.
4ii8 +xamine for twist in the chain as a whole. .everely
twisted chain or chain twisted in use by the application of
an overload while the chain has a twist in it" must be
scrapped. In the manufacture of wrought iron chain a
twist sometimes appears due to the methods of the chain
smith. For sling chain work such a twist of say half a turn
in 1)? B& may not be harmful" for other purposes such as
crane chains this degree of twist renders the chain quite
unsuitable and liable to very rapid wear.
4iii8 +xamine for cracks" scores or marks liable to
weaken the link.
4iv8 +xamine for pitting due to corrosion" whether by rust or
by acid attack.
FIG. >H
4v8 +xamine for wear.
08 'pply 3roof -oad.
FIG.1)
+8 +xamine the chain" link by link for small cracks" faulty welds etc.
In wrought Iron 2hain the following points should be searched
forD%
4i8 Transverse cracks on the outside of the weld end usually
due to overheating in welding.
4ii8 Fine hair cracks at the weld end.
FIG. >I
4iii8 2racks or opening across the end of the link remote from
the weld" due to hot shortness or faulty working of the
material.
4iv8 Incomplete adhesion of the scarf weld. This is often very
difficult to !udge as the mere fact that the line of the scarf
can be seen does not by any means indicate a bad weld.
-ifting of the scarf ends is usually a bad sign" particularly
if it taken place after the proof load has been applied.
+ven if this lifting does not indicate internal faults it
constitutes a $nick& which may develop into a source of
weakness. The soundness of a scarf weld can best be
determined by an examination of the inside of the link. If
the centre of the weld has not taken properly it is most
likely that the area of non%adhesion will come to the
surface at this point"
due probably to the fact that in working a weld the smith
finds it more difficult to strike effective blows on the
inside than on the outside of the link. 2onsequently the
outside tends a stick first" any slag or impurities which
may be preventing a proper weld in the centre would then
be forced out through the less worked inside part of the
weld preventing welding at that point. 'lternatively" if an
FIG. @B
attempt is made to weld with insufficient heat the outside
or top of the link is more likely to !oin than the centre and
inside.
4v8 5ad shaping of the weld !oint too large causing !amming
in the next link. .i6e of weld below that of iron%causing
source of weakness. The weld is correct si6e but due to
bad tooling the material is reduced in si6e of the weld.
4vi8 -ongitudinal scams in the iron tending to open. #ther
faults in the iron such as unwelded pilings
4vii8 #verheated or burned welds which can usually be
recogni6ed by a fused and glossy appearance.
F8 In the case of steel chains the following points should be searched
forD%
4i8 Transverse cracks across the crowns or ends of the links
caused in bending and usually indicating unsuitable
material.
FIG. @1
4ii8 Faults at the weld. These are very difficult to detect a line
showing the !unction of the two ends must raise suspicion
to the soundness of the weld. +xamination under a
magnifying glass will help in coming to a decision. It is
often advisable to break out a sample link showing a
suspect marking and thus find whether the link in
question is faulty or not. The result of such a check can
usually be taken as applying to links in the same chain
bearing similar markings.
4iii8 5ut welds as used in steel chain are finished in a die. This
die may press the fra6ing left after butt welding back into
the still hot metal in the neighbourhood of the weld" thus
reducing the effective area of the material round the weld
and causing a nick although it may not appear on the
surface as such" due to the fact that it has been filled up
by the metal from the fra6ing. *isalignment of the dies
may cause nicks at either end of the part formed by them.
TA.LE
$roced/re for E:a'ining /#ed &(ain Sling#
Fa/lt# to 2e looked for
Wro/g(t Iron &(ain Steel &(ain
A! &(eck #i)e# wit( Ta2le#
.! &(eck for O*erloading a:! allowa2le #tretc(
FD in %ft
a:! allowa2le EG
FIG. @)
Hook# opened o/t
Di#torted fitting#
Hook# opened o/t
Di#torted fitting#
&! S/perficial E:a'ination .ent or twi#ted link#
Twi#t in &(ain
&rack#A #core# and ot(er da'age
&orro#ionA pitting and
e:ce##i*e wear
.ent or twi#ted link#
&rack#A #core# and
ot(er da'age
&orro#ionA pitting and
e:ce##i*e wear
D! $roof Te#t
E! Detailed E:a'ination i! Tran#*er#e crack# at
weld
ii! (air crack# at weld
iii! Tran#*er#e crack# at
/nwelded and
i*! Scarf lifting at end!
&rack or gap in #carf
in#ide link
*! "ntid+ weld
*i! La'inated iron
*ii!./rned weld#
i! Tran#*er#e crack#
ii! Weld fa/lt#
iii! Nick# and tool 'ark# in
Weld area
TA.LE
$roced/re for E:a'ining New &(ain Sling#
Fa/lt# to 2e looked for
Wro/g(t Iron &(ain ild Steel &(ain
A! &(eck #i)e wit( Drawing
or wit( Ta2le#
.! Not applica2le
&! S/perficial E:a'ination Twi#ted c(ain
&onnecting link# not working freel+ in c(ain or eac( ot(er
D! $roof Te#t
E! Detailed E:a'ination A# in Ta2le II 2/t in addition partic/larl+ noting an+ #ign# of
#tretc( or di#tortion in (ook# or fitting# after $roof Load w(ic(
wo/ld #(ow /p po##i2le 'i#take# in de#ign!
Wear in &(ain Link#
FIG. @<
It has been widely stated that the allowable wear should not exceed 1BF.
This is an extremely loose statement and enquiry reveals that there is
considerable variation in the interpretation of this rule. It is sometimes taken
that the 1BF refers to the diameter" while by others it is assumed to be the
area. Furthermore the real meaning of 1BF reduction in area needs to be
made clear. =hen a chain link wears at the crown the area is reduced in the
manner shown in Fig. below" at $'& and not usually as at $5& or $2&. For a
given reduction of diameter as measured by a caliper on the sections $'&"
$5& and $2&" each has a different area" $'& having a greater area than $5&
and is consequently the stronger.
FIG.1<
In the statement which follows it is assumed that the wear is as $'&. '
reduction of 1BF of the area in this manner gives a loss of strength of )BF
somewhat too much for wrought iron chain when it is considered that the
amount of wear would be the starting point of a further period of service"
during which the wear might well reach really dangerous figures. The
conversion of loss in area to the equivalent loss in diameter is a complicated
mathematical procedure. It is therefore suggested that a figure of
1
(
1B
& per 1&
of diameter be adopted as the maximum amount of wear allowable for
FIG. @>
wrought iron chain. This gives a loss of strength on a standard link of
approximately 1BF.
The wear inside the ends of a wrought iron link is partly compensated for by
the bar iron which it is made being normally
1
(
@)
& larger in diameter than the
nominal si6e of the chain. 's the wear allowance is based on the nominal
diameter of the chain a certain amount of wear can take place before the link
is reduced even to its nominal diameter.
The welds in wrought iron chain being at the crown of the link are sub!ect to
wear consequently there is a real danger that where there is incomplete
adhesion at the weld the wear may remove part of the meal which has !oined
at the surface" thus learning the unstuck center to take the load. It is
important that the worn surface of end weld links be very carefully
examined and wherever the outline of the weld can be seen on the worn
surface the link should be scrapped.
In the case of steel chain rather more wear is sometimes allowed" the
argument advanced being that the wear in wrought iron chain comes on the
weld whereas it does not in steel chain. ' reduction of HF on the diameter is
now generally accepted as the maximum permissible wear for this material"
giving a theoretical loss of strength of about 1IF. This might be
unsatisfactory were it not for the fact that experiments have shown that the
theoretical loss of strength is not borne out in practice due probably to the
fact that when wear takes place the links tend to bed down on one another"
thus spreading the load over a wider area than is allowed for in theoretical
calculations.
FIG. @@
The figures given in the following table should be treated as a maximum and
consideration should always be given to making a lesser wear allowance in
particular circumstances" such as the followingD%
a8 =hen the rate of wear is known to be rapid and the loss of strength
might reach dangerous proportions before the chain is due for
examination again.
b8 =here the chain is sub!ected to shocks or is used in conditions
where there is any special risk to life involved.
c8 =here the wear affects smooth working of link into link.
d8 =here the metal has flowed over the edges of the worn portions. In
steel chain this is often associated with microscopic cracks in the
surface.
TA.LE IBA $er'i##i2le Wear on &(ain Link#
Si)e
Of
&(ain
ini'/' Di'en#ion
o*er &ro##1Section Si)e
Of
&(ain
ini'/' Di'en#ion
o*er &ro##1Section!
Wro/g(t Iron
&(ain
85FG Wear9
Steel &(ain
86G Wear9
Wro/g(t Iron
&(ain
85FG Wear9
Steel &(ain
86G Wear9
FIG. @E
In
In
B.)<
B.)E
B.)I
B.<@
B.>1
B.>G
B.@<
B.@I
B.E>
B.GB
B.GE
In
B.)<
B.)E
B.)I
B.<>
B.>B
B.>E
B.@)
B.@G
B.E<
B.EI
B.G@
In
)
In
B.H)
B.HH
B.I>
1.B@
1.1G
1.)I
1.>1
1.@)
1.E>
1.GE
1.HH
In
B.HB
B.HE
B.I)
1.B<
1.1@
1.)E
1.<H
1.>I
1.E1
1.G)
1.H>
.teel chain is usually manufactured from exact si6e bar" the maximum plus
tolerance on the bar si6e being >F. =hen forming the links the section of
the bar may become slightly flattened where it is pressed in contact with the
mandrel. owever the effective area of the section and consequently the
strength of the link are not significantly reduced" as the material from the
flattened area is pressed outward but not removed. =hen considering the
minus tolerance to be allowed on new links" allowance has to be made for
these circumstances" and it will be appreciated that it must be based on the
mean diameter rather than on the minimum
This instrument used in measuring chains is essentially a calipers or
micrometer having one flat measuring face" and the other a narrow blade
shaped in a L%groove In order to standardi6e the method of making this
measurement a special instrument has been devised" and is specified to be
used for 5ritish .tandard 2hain 4see 5..@IB" 5..1EE<" 5..<11<" for Grades
<B" >B and EB" chain respectively8.
FIG. @G
of 1<@
o
angle is fitted to the inside of the link" and the flat anvil is brought
into contact with the outside. Lariation of the direction of measurement over
the range of )B
o
either side of the plane of the link makes no appreciable
difference" and since the flat anvil is too wide to go inside the link there is no
risk of the calipers or micrometer being used the wrong way round.
=hen measured by this instrument the limiting minus tolerance on new chin
is )F under the specified si6e. 0ue to the fact that the section of the link at
the crown may be slightly oval the actual minimum diameter as measured
with ordinary calipers may well show a greater reduction in diameter than
)F. The wear allowance is HF reduction in diameter" if this too is measured
with ordinary calipers it will be found that in many cases a substantial
proportion of this allowance has been absorbed by the tolerance on the new
chain. The use of a similar special instrument for measuring worn lines
ensures that due account is taken of the actual shape of the cross section.
In the case of worn link" if measurements are taken not only in the plane of
the link" but also at angles over the range of <B
o
either side of the plane of the
link" the apparent loss will vary according to the angle. 's a result of trial on
several types of wear on links" it is recommended that steel chain should be
withdrawn from service if the greatest apparent loss of diameter so
measured" exceeds )MF.
THE $RO&ED"RE FOR SETTING "$
AND WORKING A O.ILE &RANE
FIG. @H
.et on ground as near level and a close to the -oad as possible.
2heck for soft spots" also for high%tension wires and always stay as far away
from them as possible. 3ull out the outrigger and block up securely with the
crane as near level as possible.
In the case of near maximum -oads" make sure of the exact weight. It is the
duty of the rigger to be thoroughly familiar with the crane?s capacity chart
and never exceed the safe working loads.
*ake sure the load is slung correctly and see that the chokers" shackles" and
all equipment used for lifting are of sufficient si6e and strength to maintain
the proper safety factors.
=hen the load is properly slung" the foreman shall have the operator float
the load !ust clear of the ground" to check the gear clear under load and to
give the operator a chance to get the feel of it" and to satisfy himself that he
can comfortably handle the load.
#nly one man in the gang shall give signals. 4*ake sure all signals are given
clearly and correctly.8 In some cases where the operator cannot see the
signalman" another man shall be stationed where he can see both the
signalman and the operator and relay the signals to the operator.
'll gear should be inspected daily and any that is found to be faulty should
be discarded immediately.
In handing load" all safety rules shall be followed. +xplicitly work safely at
all times.
FIG. @I
FIG!%?
FIG. EB
NOTE =eight of !ib" load block" weight ball and hooks" slings" hoist lines
beneath boom and !ib point sheaves" etc. is considered part of the main load.
DES&RI$TION
%! &O$ONENT WEIGHTS
1. RI5 4see $0+0/2T F,#* 2'3'2ITI+.& on capacity chart89999..
). =+IGT 5'-- '10 ##K 4!ib point8999999
<. /33+, 5##* 3#I1T 4from capacity chart if noted8999.
>. =+IGT 5'-- '10 ##K 4upper boom point89999..
@. -#'0 5-#2K 999999999999999..
E. .-I1G. '10 *I.2+--'1+#/. -IFTI1G +S/I3*+1T 99..
G. T#T'- =+IGT =I,+ ,#3+ 5+1+'T -#=+," /33+, '10 RI5 9..
3#I1T 4see $-#'0 -I1+ .3+2IFI2'TI#1.& for weight of wire rope ft8
%%! TOTALS
'. T#T'- 2#*3#1+1T =+IGT 4add 1 thru G 8 9999999
5. =+IGT #F -#'0 T# 5+ -IFT+0 99999999999.
2. T#T'- -#'0 T# 5+ -IFT+0 4add ' and b8 99999999
0. *'AI*/* =#,KI1G ,'0I/. 4for Total -oad to be -ifted" from 2 above"
.ee correct capacity chart8 9999999999999999.
&A"TION
1. 0# 1#T 5##* #/T =IT T#T'- -#'0 T# 5+ -IFT+0 42 8 5+:#10
,'0I/. '--#=+0.
). 5##* I. 1#T T# 5+ -#=+,+0 5+:#10 ,'0II =+,+ T#T'-
2#*3#1+1T =+IGT 4'8 I. G,+'T+, T'1 ,'T+0 2'3'2IT:.
<. 5+ ./,+ T# /.+ '0+S/'T+ 3',T. #F -I1+ 4see $#I.T ,+LLI1G For
*'I1 -#'0 5-#2K& #1 capacity chart8..
FIG. E1
SELE&TION OF ABI" WORKING RADI"S 1 EBA$LE
DES&RI$TION WEIGHT 8I2#!9
&O$ONENT WEIGHTS
1. RI5 4see $0+0/2T F,#* 2'3'2IT:& on capacity chart8
99999999<BBB
). =+IGT 5'-- '10 ##K 4!ib point8
999999999999999. IBB
<. /33+, 5##* 3#I1T 4from capacity chart if noted8
9999999999. B
>. =+IGT 5'-- '10 ##K 4upper boom point8
99999999999.>"G>B
@. -#'0 5-#2K
9999999999999999999999999.. GBB
E. .-I1G. '10 *I.2+--'1+#/. -IFTI1G +S/I3*+1T 9999999.1"1>E
G. T#T'- =+IGT =I,+ ,#3+ 5+1+'T -#=+," /33+, '10 RI5
3#I1T 4see $-#'0 -I1+ .3+2IFI2'TI#1.& for weight of wire rope per ft.8
%! TOTALS
'. T#T'- 2#*3#1+1T =+IGT 4'00 1 T,/ G8 99999999999.1B">HE
5. =+IGT #F -#'0 T# 5+ -IFT+0 99999999999999999..@B"BBB
2. T#T'- -#'0 T# 5+ -IFT+0 4add ' and 58 999999999999...EB">HE
0. *'AI*/* =#,KI1G ,'0I/. 4for Total -oad to be lifted" from 2 above"
.ee correct capacity chart8 9999999999999999999999.. @@ft.
For details on inspection and testing procedures" see attached.
FIG. E)
GLOSSAR, OF TERS
ALLO, ' metal made by adding other metals or
non%metals to a base metal; thus .teel is an
'lloy of Iron and 2arbon.
ALLO, STEEL the term applied to steel to which has been
added in the course of manufacture other
elements such as *anganese" 1ickel"
2hromium etc.
Ac $OINT ' critical point occurring on heatingV
Ar $OINT ' critical point occurring on coolingV
A"STENITE The solid solution of carbon and or alloying
elements in ironV
.RINELL TEST ' test to determine hardness by pressing a
hard steel ball of known diameter under a
standard load into the surface of the material
and measuring the diameter of the
indentation produced V
FIG. E<
.RITTLENESS ' tendency to fracture without visible plastic
deformation.V
."RNING eating to such a high temperature that the
properties of the material are permanently
impaired by incipient fusion or oxide
penetration.V
&EENTITE 'n iron carbide 4a compound of iron and
carbon8 found in steel and cast iron.
&O$O"ND ' substance composed of two or more
elements in definite proportions by weight
and having its own definite properties.
D"&TILIT, The ability to undergo cold plastic
deformation usually as a result of tension.V
ELEENT ' substance which cannot be divided by
chemical means into simpler substances"
returns to its original dimensions after
removal of a stress.V
ELASTI& LIIT The highest stress which can be applied
without producing permanent deformation.V
ELONGATION The increase in length of a tensile test piece
when stressed. The elongation at fracture is
FIG. E>
usually expressed as a percentage of the
original gauge length.V
FATIG"E The failure of a metal due to the effect of
repeated alternating or cyclic stresses
considerably below the tensile strength.
FRAHING The line of metal squee6ed out between the
dies curing drop stamping.
HARDNESS ,esistance to deformation" indentation"
abrasion" cutting" etcV
HOOKEIS LAW The law stating that within the elastic range
the strain produced is proportional to the
stress. V
INGOT *etal cast in a mould of a shape suitable for
subsequent processing.
LIIT OF The stress 4load divided by the original area
$RO$ORTIONALIT, of cross section of a test piece8 at which the
strain 4elongation per unit length of original
gauge length8 ceases to be proportional to
the original stress.V
FIG. E@
ALLEA.ILIT, 2apacity for undergoing deformation in all
directions" usually cold deformation by
hammering or squee6ing.
ETALL"RGI&AL The condition of the material as regards
&ONDITION chemical condition of elements therein"
grain si6e and arrangement which will have
an effect on the physical properties such as
strength" ductility" hardness etc.
ARTENSITE The hard constituent produced when the
steel is cooled from the hardening
temperature at a speed greater than its
critical cooling rate.V
FIG. EE
FIG. EG
The Laws of the Federation of Nigeria, 1990 Chapter 126,
Factories Act
Code of Practice for the Safe use of Lifting !uip"ent #$
Lifting !uip"ent ngineers Association
%ritish Standard %S &121 Safe 'se of Cranes ( Part 1(
1990) *+enera,-
%ritish Standard %S &121 Safe 'se of Cranes ( Part
2(1991) *.nspection, testing and e/a"ination-
%ritish Standard %S &121 Safe 'se of Cranes ( Part 0(
199&) *Lorr$ Loaders-)
%ritish Standard %S &121 Safe 'se of Cranes ( Part 11(
1991) *2ffshore Cranes-)
The Chain Testers 3and#oo4 #$ C)3)A 5cCau,,$
App,ied Strength of 5ateria,s) 6
rd
dition) %$ A,fred
7ensen83) Chenoweth),
3and#oo4 for 9iggers, #$ :)+) *%i,,- New#err$